SIMULATION OF HEAT TRANSFER

PHENOMENON IN FURNACE
USING FLUENT-GAMBIT

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE DEGREE OF

Bachelor of Technology

in

Mechanical Engineering

By
PEEYUSH AGARWAL

Under the guidance of

Dr. SWARUP KUMAR MAHAPATRA

Department of Mechanical Engineering

National Institute of Technology
Rourkela
2009
1
 National Institute of Technology
Rourkela
CERTIFICATE

This is to certify that the thesis entitled “SIMULATION OF HEAT TRANSFER

IN FURNACE USING FLUENT GAMBIT”
Submitted by MR.PEEYUSH AGARWAL in partial fulfillment of the
requirements for the award of Bachelor of technology Degree in Mechanical
Engineering at the National Institute of Technology, Rourkela (Deemed
University) is an authentic work carried out by him under my supervision and
guidance. To the best of my knowledge, the matter embodied in the thesis has not
been submitted to any other University / Institute for the award of any Degree or
Diploma

DATE: Dr. SWARUP KUMAR MAHAPATRA

NATIONAL INSTITUTE OF TECHNOLOGY

ROURKELA, 769008

2
 ACKNOWLEDGEMENT

We deem it a privilege to have been the student of Mechanical Engineering stream

in
National Institute of Technology, ROURKELA
Our heartfelt thanks to Dr.S.K.MAHAPATRA, my project guide who helped us to
bring out
this project in good manner with his precious suggestion and rich experience.
We take this opportunity to express our sincere thanks to our project guide for
cooperation
in accomplishing this project a satisfactory conclusion.

Peeyush agarwal

Roll no: 10503026

MECHANICAL ENGINEERING, NIT ROURKELA

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 CONTENTS
CONTENTS………………………………………………………................................................ I
ABSTRACT………………………………………………………................................................. II
1. INTRODUCTION
1.1 THE MINIATURIZATION …………………………………………………………………. 1
1.2 BASICS OF FURNACE ……………………………………………………………………… 2
1.3 CFD PROCESS ………………………………………………………………………………… 5
1.4 GAMBIT CFD PREPROCESSOR………………………………………………….. ……. 5
2. THEORY
2.1 HOW DOES A CFD CODE WORK? …………………………………………………….6
2.1.1. PRE-PROCESSING:………………………………………………………. 6
2.1.2. SOLVER…………………………………………………………………….. .7
2.1.3 POST-PROCESSING ……………………………………………………... 10
2.1.4. ADVANTAGES OF CFD……………………………………………… .. 11
2.2 MATHEMATICAL EQUATIONS……………………………………………………. .. 11
2.2.1) ENERGY EQUATION …………………………………………………….. 13

2 .2.2) MOMENTUM EQUATIONS …………………………………………..17

2 .2.3) TURBULENCE EQUATIONS ……………………………………………18

2.2.4) SPECIES EQUATIONS …………………………………. ………………….18

2.2.5) PULL VELOCITY FOR CONTINUOUS CASTING …………………20

2.3 DISCRETIZATION METHODS IN CFD ………………………………………………….. 22

2.3.1. FINITE DIFFERENCE METHOD (FDM):………………………………22
2.3.2. FINITE VOLUME METHOD (FVM): …………………………………..22
2.3.3. FINITE ELEMENT METHOD (FEM):……...…………………………. 23
3 . PROBLEM DISCRIPTION AND SOLUTION BY GAMBIT –FLUENT
3.1)GEOMETRY AND MESH………………………… …………………………………… 25
3.2) ANALYSIS IN FLUENT…………………………………. ………………………………26
4) RESULTS
4.1: COMPARISON OF CONVEGENCERCE CURVES…………………………..33
4.2: COMAPARISON OF TIME TO BECOME STEADY………………………………34

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 4.3: COMPARSION OF TEMPERATURE AT BOTTOM WALL………………………35
4.4: COMPARISON OF THE TEMPERATURE PROFILES…………………………………36
4.5: COMPARISON OF DENSITY PROFILE …………………………………………………….37
4.6: COMPARISON OF SOLIDIFICATION-MELTING CURVE FOR VARYING
TEMPERATURE OF FURNACE………………………………………………………………………………….38
5. CONCLUSION……………………………………………………… ……………………………………………39
BIBLIOGRAPY

5
ABSTRACT

In this project work the simulation of heat transfer and the temperature curve in the furnace is
computed out using gambit and fluent software. Comparison of temperature profiles of the
material in the furnace using constant temperature heat source and linearly varying
temperature of the heat source for unsteady state is done. Also the time for temperature to
become steady is compared. The material used in the furnace is aluminum and conduction is
the mode of heat transfer, the side walls are adiabatic and maintained at ambient temperature.
Also the density variation and solidification-melting curve of material filled inside are compared
for both conditions. The geometry used is very simple, similar to muffle furnace. The problem
will be solved by using the software package FLUENT – GAMBIT.

FLUENT is a computational fluid dynamics (CFD) software package to simulate fluid problems. It
uses the finite-volume method to solve the governing equations for a fluid. It provides the
capability to use different physical models such as incompressible or compressible, in viscid or
viscous, laminar or turbulent, etc. Geometry and grid generation is done using GAMBIT which is
the preprocessor bundled with FLUENT.

6
INTRODUCTION

7
1.1 THE MINIATURIZATION

HEAT UP processing is the basic step for the workload in melting and heat treatment for further
processing. It is also an energy-intensive process. Thus, correct prediction of the temperature
variation and distribution in the workload is of significance to ensure the final quality of the
parts and to reduce energy consumption and time as well.

There are some studies about the optimization of heat treating process in furnace.
FurnXpert'11 is developed to optimize furnace design and operation for many types of
batch and continuous furnaces, such as the continuous belt furnace for sintering process
in powder metallurgy. The program mainly focuses on the heat balance of the furnace,
while, the load pattern of work pieces is just aligned load pattern in 2-dimention.

Han Xiaoliang [21 established mathematical model for the heating of workpiece in bogie
hearth heat treatment furnace, while, the workpiece is assumed to be one dimensional
and only single workpiece is considered.

Wan Nini [31 studied the heating up of steel tubes in continuous furnace annealing
furnace. The influence of moving speed and thickness of steel tubes are studied. The
heat transfer is also assumed to be one dimensional and the load pattern is simply
aligned in the width direction. In the heat treatment of parts such as castings and
forging, the load pattern is complicated with multi parts stacked in order or disorder and
the shapes of work pieces are also irregular. Then it is necessary to model the heat
transfer inside the workload.
In recent years, the computational fluid dynamics (CFD) based on conservation equations has
become a viable technique for process simulation So in this work we are going to compute the
temperature profile generated Using CFD and GAMBIT for a given temperature source, it can
help to Compute the energy required and to optimize it.

8
1.2 BASICS OF FURNACE:

A furnace is a device used for heating. The heat energy to fuel a furnace may be supplied
directly by fuel combustion, by electricity such as the electric arc furnace, or through Induction
heating in induction furnace

Industrial process furnaces:-

An industrial furnace or direct fired heater is equipment used to provide heat for a process or
can serve as reactor which provides heats of reaction. Furnace designs vary as to its function,
heating duty, type of fuel and method of introducing combustion air. However, most process
furnaces have some common features.

Fuel flows into the burner and is burnt with air provided from an air blower. There can be more
than one burner in a particular furnace which can be arranged in cells which heat a particular
set of tubes. Burners can also be floor mounted, wall mounted or roof mounted depending on
design. The flames heat up the tubes, which in turn heat the fluid inside in the first part of the
furnace known as the radiant section or firebox. In this chamber where combustion takes place,
the heat is transferred mainly by radiation to tubes around the fire in the chamber. The heating
fluid passes through the tubes and is thus heated to the desired temperature. The gases from
the combustion are known as flue gas. After the flue gas leaves the firebox, most furnace
designs include a convection section where more heat is recovered before venting to the
atmosphere through the flue gas stack.

9
10
Radiation section:

Radiation section is where the tubes receive almost all its heat by radiation from the flame. In a
vertical, cylindrical furnace, the tubes are vertical. Tubes can be vertical or horizontal, placed
along the refractory wall, in the middle, etc., or arranged in cells

Convection section

The convection section is located above the radiant section where it is cooler to recover
additional heat. Heat transfer takes place by convection here, and the tubes are finned to
increase heat transfer. The first two tube rows in the bottom of the convection section and at
the top of the radiant section is an area of bare tubes (without fins) and are known as the shield
section, so named because they are still exposed to plenty of radiation from the firebox and
they also act to shield the convection section tubes, which are normally of less resistant
material from the high temperatures in the firebox

Burner:

The burner in the vertical, cylindrical furnace as above is located in the floor and fires upward.
Some furnaces have side fired burners, e.g.: train locomotive. The burner tile is made of high
temperature refractory and is where the flame is contained in. Air registers located below the
burner and at the outlet of the air blower are devices with movable flaps or vanes that control
the shape and pattern of the flame, whether it spreads out or even swirls around

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1.3 CFD PROCESS:

Preprocessing is the first step in building and analyzing a flow model. It includes building the
model (or importing from a CAD package), applying the mesh, and entering the data. We used
Gambit as the preprocessing tool in our project.

There are four general purpose products: FLUENT, Flowizard, FIDAF, and
POLY FLOW. FLUENT is used in most industries All Fluent software includes full post processing
capabilities.

1.4 GAMBIT CFD PREPROCESSOR:

Fast geometry modeling and high quality meshing are crucial to successful use of
CFD.GAMBIT gives us both. Explore the advantage:
Ease of use
CAD/CAE Integration
Fast Modeling
CAD Cleanup
Intelligent Meshing
EASE-OF-USE
GAMBIT has a single interface for geometry creation and meshing that brings together all of
Fluent’s preprocessing technologies in one environment. Advanced tools for journaling let us
edit and conveniently replay model building sessions for parametric studies.

12
THEORY

13
2.1 How does a CFD code work?

CFD codes are structured around the numerical algorithms that can be tackle fluid
problems. In order to provide easy access to their solving power all commercial CFD packages
include sophisticated user interfaces input problem parameters and to examine the results.
Hence all codes contain three main elements:
1. Pre-processing.
2. Solver
3. Post-processing.

2.1.1. Pre-Processing:
This is the first step in building and analyzing a flow model. Preprocessor consist of input
of a flow problem by means of an operator –friendly interface and subsequent transformation
of this input into form of suitable for the use by the solver. The user activities at the Pre-
processing stage involve:
• Definition of the geometry of the region: The computational domain.
• Grid generation the subdivision of the domain into a number of smaller, non-
overlapping sub domains (or control volumes or elements Selection of physical or chemical
phenomena that need to be modeled).
• Definition of fluid properties
• Specification of appropriate boundary conditions at cells, which coincide with or touch
the boundary. The solution of a flow problem (velocity, pressure, temperature etc.) is defined
at nodes inside each cell. The accuracy of CFD solutions is governed by number of cells in the
grid. In general, the larger numbers of cells better the solution accuracy. Both the accuracy of
the solution & its cost in terms of necessary computer hardware & calculation time are
dependent on the fineness of the grid. Efforts are underway to develop CFD codes with a (self)
adaptive meshing capability. Ultimately such programs will automatically refine the grid in
areas of rapid variation.

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 GAMBIT (CFD PREPROCESSOR): GAMBIT is a state-of-the-art preprocessor for engineering
analysis. With advanced geometry and meshing tools in a powerful, flexible, tightly-integrated,
and easy-to use interface, GAMBIT can dramatically reduce preprocessing times for many
applications. Complex models can be built directly within GAMBIT’s solid geometry modeler, or
imported from any major CAD/CAE system. Using a virtual geometry overlay and advanced
cleanup tools, imported geometries are quickly converted into suitable flow domains. A
comprehensive set of highly-automated and size function driven meshing tools ensures that the
best mesh can be generated, whether structured, multiblock, unstructured, or hybrid.

2.1.2. Solver:
The CFD solver does the flow calculations and produces the results. FLUENT, FloWizard,
FIDAP, CFX and POLYFLOW are some of the types of solvers. FLUENT is used in most industries.
FloWizard is the first general-purpose rapid flow modeling tool for design and process
engineers built by Fluent. POLYFLOW (and FIDAP) are also used in a wide range of fields, with
emphasis on the materials processing industries. FLUENT and CFX two solvers were developed
independently by ANSYS and have a number of things in common, but they also have some
significant differences. Both are control-volume based for high accuracy and rely heavily on a
pressure-based solution technique for broad applicability. They differ mainly in the way they
integrate the fluid flow equations and in their equation solution strategies. The CFX solver uses
finite elements (cell vertex numerics), similar to those used in mechanical analysis, to discretize
the domain. In contrast, the FLUENT solver uses finite volumes (cell centered numerics). CFX
software focuses on one approach to solve the governing equations of motion (coupled
algebraic multigrid), while the FLUENT product offers several solution approaches (density-,
segregated- and coupled-pressure-based methods)

The FLUENT CFD code has extensive interactivity, so we can make changes to the analysis
at any time during the process. This saves time and enables to refine designs more efficiently.
Graphical user interface (GUI) is intuitive, which helps to shorten the learning curve and make
the modeling process faster. In addition, FLUENT's adaptive and dynamic mesh capability is

15
unique and works with a wide range of physical models. This capability makes it possible and
simple to model complex moving objects in relation to flow. This solver provides the broadest
range of rigorous physical models that have been validated against industrial scale applications,
so we can accurately simulate real-world conditions, including multiphase flows, reacting flows,
rotating equipment, moving and deforming objects, turbulence, radiation, acoustics and
dynamic meshing. The FLUENT solver has repeatedly proven to be fast and reliable for a wide
range of CFD applications. The speed to solution is faster because suite of software enables us
to stay within one interface from geometry building through the solution process, to post-
processing and final output.

The numerical solution of Navier–Stokes equations in CFD codes usually implies a

discretization method: it means that derivatives in partial differential equations are
approximated by algebraic expressions which can be alternatively obtained by means of the
finite-difference or the finite-element method. Otherwise, in a way that is completely different
from the previous one, the discretization equations can be derived from the integral form of
the conservation equations: this approach, known as the finite volume method, is implemented
in FLUENT (FLUENT user’s guide, vols. 1–5, Lebanon, 2001), because of its adaptability to a wide
variety of grid structures. The result is a set of algebraic equations through which mass,
momentum, and energy transport are predicted at discrete points in the domain. In the
freeboard model that is being described, the segregated solver has been chosen so the
governing equations are solved sequentially. Because the governing equations are non-linear
and coupled, several iterations of the solution loop must be performed before a converged
solution is obtained and each of the iteration is carried out as follows:
(1) Fluid properties are updated in relation to the current solution; if the calculation is at
the first iteration, the fluid properties are updated consistent with the initialized solution.
(2) The three momentum equations are solved consecutively using the current value for
pressure so as to update the velocity field.
(3) Since the velocities obtained in the previous step may not satisfy the continuity
equation, one more equation for the pressure correction is derived from the continuity

16
equation and the linearized momentum equations: once solved, it gives the correct pressure so
that continuity is satisfied. The pressure–velocity coupling is made by the SIMPLE algorithm, as
in FLUENT default options.
(4) Other equations for scalar quantities such as turbulence, chemical species and
radiation are solved using the previously updated value of the other variables; when inter-
phase coupling is to be considered, the source terms in the appropriate continuous phase
equations have to be updated with a discrete phase trajectory calculation.
(5) Finally, the convergence of the equations set is checked and all the procedure is
repeated until convergence criteria are met. (Ravelli et al., 2008)

Set the solution parameters

Initialize the solution

Enable the solution monitors of interest

Calculate a solution
Modify solution parameters
or grid

Check for convergence

No
Yes

Check for accuracy

Yes No

Stop

Fig.4. Algorithm of numerical approach used by simulation softwares

17
 The conservation equations are linearized according to the implicit scheme with respect
to the dependent variable: the result is a system of linear equations (with one equation for
each cell in the domain) that can be solved simultaneously. Briefly, the segregated implicit
method calculates every single variable field considering all the cells at the same time. The code
stores discrete values of each scalar quantity at the cell centre; the face values must be
interpolated from the cell centre values. For all the scalar quantities, the interpolation is carried
out by the second order upwind scheme with the purpose of achieving high order accuracy. The
only exception is represented by pressure interpolation, for which the standard method has
been chosen. Ravelli et al., 2008)

2.1.3 Post-Processing:
This is the final step in CFD analysis, and it involves the organization and interpretation
of the predicted flow data and the production of CFD images and animations. Fluent's software
includes full post processing capabilities. FLUENT exports CFD's data to third-party post-
processors and visualization tools such as Ensight, Fieldview and TechPlot as well as to VRML
formats. In addition, FLUENT CFD solutions are easily coupled with structural codes such as
ABAQUS, MSC and ANSYS, as well as to other engineering process simulation tools.
Thus FLUENT is general-purpose computational fluid dynamics (CFD) software ideally
suited for incompressible and mildly compressible flows. Utilizing a pressure-based segregated
finite-volume method solver, FLUENT contains physical models for a wide range of applications
including turbulent flows, heat transfer, reacting flows, chemical mixing, combustion, and
multiphase flows. FLUENT provides physical models on unstructured meshes, bringing you the
benefits of easier problem setup and greater accuracy using solution-adaptation of the mesh.
FLUENT is a computational fluid dynamics (CFD) software package to simulate fluid flow
problems. It uses the finite-volume method to solve the governing equations for a fluid. It
provides the capability to use different physical models such as incompressible or compressible,
inviscid or viscous, laminar or turbulent, etc. Geometry and grid generation is done using
GAMBIT which is the preprocessor bundled with FLUENT. Owing to increased popularity of

18
engineering work stations, many of which has outstanding graphics capabilities, the leading CFD
are now equipped with versatile data visualization tools. These include
• Domain geometry & Grid display.
• Vector plots.
• Line & shaded contour plots.
• 2D & 3D surface plots.
• Particle tracking.
• View manipulation (translation, rotation, scaling etc.)

2.1.4. Advantages of CFD:

Major advancements in the area of gas-solid multiphase flow modeling offer substantial
process improvements that have the potential to significantly improve process plant
operations. Prediction of gas solid flow fields, in processes such as pneumatic transport lines,
risers, fluidized bed reactors, hoppers and precipitators are crucial to the operation of most
process plants. Up to now, the inability to accurately model these interactions has limited the
role that simulation could play in improving operations. In recent years, computational fluid
dynamics (CFD) software developers have focused on this area to develop new modeling
methods that can simulate gas-liquid-solid flows to a much higher level of reliability. As a result,
process industry engineers are beginning to utilize these methods to make major
improvements by evaluating alternatives that would be, if not impossible, too expensive or
time-consuming to trial on the plant floor. Over the past few decades, CFD has been used to
improve process design by allowing engineers to simulate the performance of alternative
configurations, eliminating guesswork that would normally be used to establish equipment
geometry and process conditions. The use of CFD enables engineers to obtain solutions for

19
problems with complex geometry and boundary conditions. A CFD analysis yields values for
pressure, fluid velocity, temperature, and species or phase concentration on a computational
grid throughout the solution domain. Advantages of CFD can be summarized as:
1. It provides the flexibility to change design parameters without the expense of hardware
changes. It therefore costs less than laboratory or field experiments, allowing engineers to try
more alternative designs than would be feasible otherwise.
2. It has a faster turnaround time than experiments.
3. It guides the engineer to the root of problems, and is therefore well suited for trouble-
shooting.
4. It provides comprehensive information about a flow field, especially in regions where
measurements are either difficult or impossible to obtain.

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2.2) MATHEMATICAL EQUATIONS

2.2.1) Energy Equation

The enthalpy of the material is computed as the sum of the sensible enthalpy, , and the
latent heat, :

(1)

(2)

and = reference enthalpy

= reference temperature

= specific heat at constant pressure

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The liquid fraction, , can be defined as

(-3)

Equation 3 is referred to as the lever rule .

The latent heat content can now be written in terms of the latent heat of the material, :

(4)

The latent heat content can vary between zero (for a solid) and (for a liquid).

In the case of multi component solidification with species segregation; i.e., solidification or
melting with species transport, the solidus and liquidus temperatures are computed instead of
specified

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 (5)

(6)

where ki is the partition coefficient of solute , which is the ratio of the concentration in solid
to that in liquid at the interface, yi is the mass fraction of solute , and mi is the slope of
the liquidus

surface with respect to yi. It is assumed that the last species material of the mixture is the
solvent and that the other species are the solutes.

For solidification/melting problems, the energy equation is written as

(7)

where = enthalpy (see Equation 1)

= density

= fluid velocity

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 = source term

The solution for temperature is essentially an iteration between the energy equation (Equation
7) and the liquid fraction equation (Equation 3). Directly using Equation 3 to update the liquid
fraction usually results in poor convergence of the energy equation. In FLUENT, the method
suggested by Voller and Swaminathan [ 386] is used to update the liquid fraction. For pure

metals, where and are equal, a method based on specific heat, given by
Voller and Prakash [ 385], is used instead.

24
2 .2.2) Momentum Equations

The enthalpy-porosity technique treats the mushy region (partially solidified region) as a porous
medium. The porosity in each cell is set equal to the liquid fraction in that cell. In fully solidified
regions, the porosity is equal to zero, which extinguishes the velocities in these regions. The
momentum sink due to the reduced porosity in the mushy zone takes the following form:

(8)

where is the liquid volume fraction, is a small number (0.001) to prevent division by zero,

is the mushy zone constant, and is the solid velocity due to the pulling of solidified
material out of the domain (also referred to as the pull velocity ).

The mushy zone constant measures the amplitude of the damping; the higher this value, the
steeper the transition of the velocity of the material to zero as it solidifies. Very large values
may cause the solution to oscillate.

The pull velocity is included to account for the movement of the solidified material as it is
continuously withdrawn from the domain in continuous casting processes. The presence of this
term in Equation 8 allows newly solidified material to move at the pull velocity. If solidified

material is not being pulled from the domain, . More details about the pull velocity are
provided in Section 5.

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2.2.3) Turbulence Equations

Sinks are added to all of the turbulence equations in the mushy and solidified zones to account
for the presence of solid matter. The sink term is very similar to the momentum sink term
(Equation 24.2-8):

(9)

where represents the turbulence quantity being solved ( , , , etc.), and the mushy

zone constant, , is the same as the one used in Equation 8.

2.2.4 ) Species Equations

In the case of solidification/melting with species transport, the following species equation is
solved:

(10)

where is given by

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 (11)

Here is the average species mass fraction in a cell:

(12)

and are related by the partition coefficient :

(13)

is the velocity of the liquid and is the solid (pull) velocity. is set to zero if pull
velocities are not included in the solution. The liquid velocity can be found from the average
velocity (as determined by the flow equation) as

(14)

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2.2.5) Pull Velocity for Continuous Casting

In continuous casting processes, the solidified matter is usually continuously pulled out from
the computational domain, as shown in Figure 24.2.1. Consequently, the solid material will
have a finite velocity that needs to be accounted for in the enthalpy-porosity technique.

Figure 24.2.1: "Pulling'' a Solid in Continuous Casting

As mentioned in Section 2, the enthalpy-porosity approach treats the solid-liquid mushy zone
as a porous medium with porosity equal to the liquid fraction. A suitable sink term is added in
the momentum equation to account for the pressure drop due to the porous structure of the
mushy zone. For continuous casting applications, the relative velocity between the molten
liquid and the solid is used in the momentum sink term (Equation 8) rather than the absolute
velocity of the liquid.

The exact computation of the pull velocity for the solid material is dependent on the Young's
modulus and Poisson's ratio of the solid and the forces acting on it. FLUENT uses a Laplacian
equation to approximate the pull velocities in the solid region based on the velocities at the
boundaries of the solidified region:

28
 (15)

FLUENT uses the following boundary conditions when computing the pull velocities:

• At a velocity inlet, a stationary wall, or a moving wall, the specified velocity is used.
• At all other boundaries (including the liquid-solid interface between the liquid and
solidified material), a zero-gradient velocity is used.

The pull velocities are computed only in the solid region.

Note that FLUENT can also use a specified constant value or custom field function for the pull
velocity, instead of computing it. See Section 2 for details.

29
(2.3)Discretization Methods in CFD
There are three discretization methods in CFD:
1. Finite difference method (FDM)
2. Finite volume method (FVM)
3. Finite element method (FEM)

2.3.1. Finite difference method (FDM): A finite difference method (FDM) discretization is
based upon the differential form of the PDE to be solved. Each derivative is replaced with an
approximate difference formula (that can generally be derived from a Taylor series expansion).
The computational domain is usually divided into hexahedral cells (the grid), and the solution
will be obtained at each nodal point. The FDM is easiest to understand when the physical grid is
Cartesian, but through the use of curvilinear transforms the method can be extended to
domains that are not easily represented by brick-shaped elements. The discretization results in
a system of equation of the variable at nodal points, and once a solution is found, then we have
a discrete representation of the solution.

2.3.2. Finite volume method (FVM): A finite volume method (FVM) discretization is based
upon an integral form of the PDE to be solved (e.g. conservation of mass, momentum, or
energy). The PDE is written in a form which can be solved for a given finite volume (or cell). The
computational domain is discretized into finite volumes and then for every volume the
governing equations are solved. The resulting system of equations usually involves fluxes of the
conserved variable, and thus the calculation of fluxes is very important in FVM. The basic
advantage of this method over FDM is it does not require the use of structured grids, and the

30
effort to convert the given mesh in to structured numerical grid internally is completely
avoided. As with FDM, the resulting approximate solution is a discrete, but the variables are
typically placed at cell centers rather than at nodal points. This is not always true, as there are
also face-centered finite volume methods. In any case, the values of field variables at non-
storage locations (e.g. vertices) are obtained using interpolation.

2.3.3. Finite element method (FEM): A finite element method (FEM) discretization is
based upon a piecewise representation of the solution in terms of specified basis functions. The
computational domain is divided up into smaller domains (finite elements) and the solution in
each element is constructed from the basis functions. The actual equations that are solved are
typically obtained by restating the conservation equation in weak form: the field variables are
written in terms of the basis functions, the equation is multiplied by appropriate test functions,
and then integrated over an element. Since the FEM solution is in terms of specific basis
functions, a great deal more is known about the solution than for either FDM or FVM. This can
be a double-edged sword, as the choice of basis functions is very important and boundary
conditions may be more difficult to formulate. Again, a system of equations is obtained (usually
for nodal values) that must be solved to obtain a solution.
Comparison of the three methods is difficult, primarily due to the many variations of all
three methods. FVM and FDM provide discrete solutions, while FEM provides a continuous (up
to a point) solution. FVM and FDM are generally considered easier to program than FEM, but
opinions vary on this point. FVM are generally expected to provide better conservation
properties, but opinions vary on this point also.

31
PROBLEM DISCRIPTION AND SOLUTION
BY GAMBIT –FLUENT

32
Problem description

The problem is to simulate the heat transfer and the temperature curve in the furnace using
gambit and fluent software. Comparison of temperature profiles of the material in the furnace
using constant temperature heat source and linearly varying temperature of the heat source for
unsteady state is found out. Also the time for temperature to become steady is compared. The
material used in the furnace is aluminum and conduction is the mode of heat transfer, the side
walls are adiabatic and maintained at ambient temperature. Also the density variation and
solidification-melting curve of material filled inside are compared for both conditions
1m

1m

(wall bottom)
Heat source

33
THE DEFAULT MATERIAL USED INSIDE IS ALUMINIUM
Simulation:

3.1)GEOMETRY AND MESH

GAMBIT 2.2.30 was used for making 2D rectangular geometry with width of 1m and height 1 m, t
geometry was later meshed into 20x20 cells.

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3.2 )ANALYSIS IN FLUENT

PROCEDURE: (2D VERSION OF FLUENT)

STEP 1: (GRID)

FILE READ CASE

The file channel mesh is selected by clicking on it under files and
Then ok is clicked.
The grid is checked.

GRID CHECK
The grid was scaled to 1 in all x, y and z directions.

GRID SCALE
The grid was displayed.

DISPLAY GRID
Grid is copied in ms-word file.

STEP 2 :( Models)
The solver was specified.

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DEFINE MODELS SOLVER
Solver is segregated
Implicit formulation
Space steady
Time steady

DEFINE MODEL ENERGY

Energy equation is clicked on.

DEFINE MODELS SOLIDIFICATION AND MELTING

STEP 3:(Materials)

the material selected was ALUMINIUM with properties.

Dynamic Viscosity, µ = 1.7894 x 10-5

Density, = 2700-.1*T
Thermal Conductivity, K=237 W/mK
Specific heat, Cp= 897 J/kg- K
Melting heat=400000 j/kg
Solidus temperature= 933.47 k
Liquidus temperature= 933.47 k

STEP 4(Operating conditions)

Operating pressure= 101.325 KPa
Gravity = -9.81 m/s2 in Y-direction

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STEP 5:(Boundary conditions)
DEFINE BOUNDARY CONDITIONS
ALUMINIUM
Set option is clicked

Default Interior
Set option is clicked

Velocity inlet.
Y -component of velocity= .001ml s.
Temperature =300 k

Wall out
Thermal conditions are temperature
Temperature =1400 k
Wall thickness= .2m
Heat generation=0

SIDE WALLS
Thermal conditions are temperature
Temperature =300k
Wall thickness= .2m
Heat generation=0

STEP 6: (custom field function)

Define temperature with x coordinates
Field function= grid
Define function to be ,T= (x + .5) * 1400 + 700

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STEP 6: (Solution)
SOLVE CONTROLS SOLUTIONS
All energy equation used.
Under relaxation factors
Pressure= 0.3
Density= 1
Body Force= 1
Momentum= .7
SOLVE INTIALIZE
Compute from –all zones
Temperature=300 k
Click INIT

STEP 7: (adapt)
ADAPT BOUNDRY ADAPTION
Boundary zone= wall out
CLICK MARK APPLY

STEP 8: (PATCH)

SOLVE INTIALIZE PATCH

Patch temperature with boundary wall out

STEP 9: (ITERATE)

SOLVE ITERATE
Input 100 as the number of iterations and iterate was clicked.
For patch function and without patch function, Convergence was checked.

FILE WRITE DATA

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STEP 10:(Displaying the preliminary solution)
Display of filled contours of velocity magnitude
DISPLAY CONTOURS
Display of filled contours of temperature
DISPLAY CONTOURS
~Temperature was selected and then
1. Static temperature.
2. Total temperature from drop down list was selected
~Display was clicked.
Display of filled contours of temperature

DISPLAY CONTOURS
~density was selected and then
~Display was clicked.
Display of filled contours density
DISPLAY CONTOURS
~solidification-melting was selected and then
1. liquid fraction.
~Display was clicked.

PLOTXY PLOT
Y AXIS-TEMPERATURE
X AXIS-GRID
1.X AXIS= X CORDINATE
2. X AXIS= Y CORDINATE

Find the temperature on a line varying x coordinates and y coordinates

39
RESULTS

40
The study work included the comparison of various graphs for the two conditions;
the various graphs are plotted in the following pattern.

SLNO FIG NO DISCRIPTION

1 1,2 COMPARISON CONVEGENCERCE CURVES

2 3,4 COMAPARISON OF TIME TO BECOME STEADY

3 5,6 COMPARSION OF TEMPERATURE AT BOTTOM WALL

4 7,8 COMPARISON OF THE TEMPERATURE PROFILES

5 9,10 COMPARISON OF DENSITY PROFILE

6 11 COMPARISON OFSOLIDIFICATION-MELTING CURVE

FOR VARYING TEMPERATURE OF FURNACE

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 4.1: COMPARISON OF CONVEGENCERCE CURVES

FIG1: THE GRAPH WAS CONVERGED WITH A CONSTANT TEMPERATURE OF

BOTTOM WALL =1400 K

FIG2: THE GRAPH WAS CONVERGED WITH LINEARLY VARYING TEMPERATURE

OF BOTTOM WALL, T= (x + .5) * 1400 + 700, X IS THE CORDINATE IN X DIRECTION

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 4.2: COMAPARISON OF TIME TO BECOME STEADY

FIG 3: THE TIME FOR TEMPERATURE TO BECOME STEADY WITH A CONSTANT

TEMPERATURE OF BOTTOM WALL =1400 K WITH Y COORDINATE, T=490 ITERATION WITH
TIME STEP =1 SECOND

FIG 4: THE TIME FOR TEMPERATURE TO BECOME STEADY WITH A TEMPERATURE OF

BOTTOM WALL, T = (x + .5) * 1400 + 700, FOR X=0, WITH Y COORDINATE, T=450
ITERATION WITH TIME STEP =1 SECOND

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 4.3: COMPARSION OF TEMPERATURE AT BOTTOM WALL

FIG 5: TEMPERATURE OF THE BOTTOM WALL AT STEADY CONDITION WITH WALL

TEMPERATURE=1400K

FIG 6 :THE TEMPERATURE OF THE BOTTOM WALL AT STEADY CONDITION WITH THE
TEMPERATURE, T= (x + .5) * 1400 + 700

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 4.4: COMPARISON OF THE TEMPERATURE PROFILES

FIG 7: TEMPERATURE PROFILE OF THE FLUID INSIDE FURNACE AT CONSTANT BOTTOM

WALL TEMPERATURE AND AT STEADY CONDITION

FIG8:TEMPERATURE PROFILE OF THE FLUID INSIDE FURNACE AT BOTTOM WALL

TEMPERATURE T =(x + .5) * 1400 + 700 AND AT STEADY CONDITION

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 4.5: COMPARISON OF DENSITY PROFILE

FIG9:THE DENSITY CURVE OF THE FLUID AT CONSTANT TEMPERATURE OF BOTTOM WALL,

T =1400K AND AT STEADY CONDITION

THE DENSITY CURVE OF THE FLUID AT TEMPERATURE T= (x + .5) * 1400 + 700 OF BOTTOM
WALL,

46
 4.6: COMPARISON OF SOLIDIFICATION-MELTING CURVE FOR VARYING
TEMPERATURE OF FURNACE

SOLIDIFICATION MELTING CURVE OF THE FLUID AT VARYING TEMPERATURE,

T= (x + .5) * 1400 + 700

47
COMPARISON CONVEGENCERCE CURVES
The graphs got converged properly for constant temperature at bottom wall also at linearly
varying temperature of the bottom wall. The graph for constant temperature was converged for
490 steps of time step of 1 second, while the graph for linearly varying temperature was
converged for 450 steps of a time step of 1 second.

COMAPARISON OF TIME TO BECOME STEADY

The graph for temperature of a line drawn at the centre of the furnace at steady condition was
compared, varying ‘y’ coordinates keeping ‘x’ coordinate to be fixed. It was found that the curve
for constant bottom temperature =1400 k got steady at time of 490 seconds while the temperature
got steady for linearly varying temperature at bottom wall at a time of 450 seconds.

COMPARSION OF TEMPERATURE AT BOTTOM WALL

The graph for temperature at the bottom wall for steady condition for a fixed temperature of

1400k was found, and the maximum temperature computed at the center was found to be 980 k

while the maximum temperature at the bottom of the wall for linearly varying temperature was

found to be 1050 k.

COMPARISON OF THE TEMPERATURE PROFILES

The graph for the temperature of the fluid at constant temperature and linearly varying

temperature was found out. The maximum temperature was found at the bottom of the wall and

at the middle of it which was 978 k and maximum temperature for linearly varying temperature

was found out to be 1040 k

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COMPARISON OF DENSITY PROFILE

The density for both the cases was almost similar with lesser density on the right side of the

furnace in the linearly increasing temperature case.

COMPARISON OF SOLIDIFICATION-MELTING CURVE FOR VARYING

TEMPERATURE OF FURNACE

It was found out that there was no liquefaction in case of constant temperate of bottom wall at

temperature of1400 k while the liquefaction was found out in linearly varying temperature at

bottom of wall

49
RESULTS AND CONCLUSION

50
The temperature profiles, density, solidification-melting and temperature at the bottom of the

wall and the time for the temperature to become steady for a constant temperature and linearly

increasing temperature are compared. It was found that:

• The graph for constant temperature was converged for 490 steps of time step of 1 second,
while the graph for linearly varying temperature was converged for 450 steps of a time
step of 1 second.
• Temperature at the bottom wall for steady condition for a fixed temperature of 1400k was

found, and the maximum temperature computed at the center was found to be 980 k while

the maximum temperature at the bottom of the wall for linearly varying temperature was

found to be 1050 k.

• The density for both the cases was almost similar with lesser density on the right side of

the furnace in the linearly increasing temperature case.

• It was found out that there was no liquefaction in case of constant temperate of bottom

wall at temperature of1400 k while the liquefaction was found out in linearly varying

temperature at bottom of wall.

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 BIBLIOGRAPHY

• www.fluent.com/ software/ gambit.

• Numerical Heat Transfer and Fluid Flow by Suhas V. Patankar
• www.wikipedia.org
• Heat transfer by– P.K NAG

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